Optical Fiber Embedded in FRP Composite for High Density
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Solution Overview
Problem
Conventional optical fiber cables have a low fiber density to cable cross-section ratio, leading to increased diameter, weight, and installation costs due to the use of multiple protective elements, which limits their capacity and efficiency in aerial and duct installations.
Innovation Solution
The use of fiber-reinforced polymer (FRP) in the optical fiber unit, where optical fibers are embedded within an FRP cross-section during the Pultrusion process, providing enhanced mechanical protection and allowing for a more compact cable design with adjustable fiber placement and cross-sectional shape, reducing the need for additional protective elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple protective elements (aramid fibers, FRP, moisture-proof tape, individual protective covers) are used in conventional optical fiber cables, then mechanical strength and environmental resistance are improved, but cable diameter and weight increase
Solution Approach 1:
The patent combines multiple protective functions into a single integrated FRP (fiber-reinforced polymer) structure. The FRP simultaneously provides mechanical strength, moisture resistance, and physical protection, eliminating the need for separate aramid fibers, moisture-proof tape, and individual protective covers. This merging reduces cable weight while maintaining protective capabilities.
Solution Approach 2:
The patent uses FRP as a composite material that integrates reinforcement fibers within a polymer matrix. This composite structure provides both mechanical strength and environmental resistance in a single material system, replacing multiple separate protective elements and reducing overall cable weight.
2Strength
If multiple protective elements are used in conventional optical fiber cables, then mechanical strength and environmental resistance are improved, but cable diameter increases
Solution Approach 1:
The patent merges multiple protective functions into a single FRP structure with integrated strength members. This consolidation reduces the overall cable diameter by eliminating gaps and redundant protective layers while maintaining mechanical strength through the FRP's inherent structural properties.
Solution Approach 2:
The patent positions optical fibers strategically within the FRP cross-section to optimize space utilization. By arranging fibers in specific locations within the FRP structure, the cable achieves maximum protective coverage with minimum diameter, improving fiber density without compromising strength.
3Reliability
If individual protective covers are used for each optical fiber, then fiber protection is improved, but fiber density to cable cross-section ratio decreases
Solution Approach 1:
The patent combines multiple optical fibers into a single FRP-encased unit rather than providing individual covers for each fiber. This approach maintains fiber protection through the FRP's robust structure while significantly increasing fiber density by allowing multiple fibers to be packed closely together without individual protective layer spacing.
Solution Approach 2:
The patent groups fibers into bundles within the FRP structure, where each bundle is protected as a unit. This segmentation allows for efficient space utilization and high fiber density while maintaining protection through the collective FRP enclosure rather than individual fiber covers.
4Strength
If conventional protective structures are used, then mechanical protection is improved, but installation cost and complexity increase
Solution Approach 1:
The patent combines multiple protective functions into a single FRP structure that requires fewer assembly steps during installation. The integrated design eliminates the need to separately install aramid fibers, moisture-proof tape, and individual protective covers, thereby reducing installation complexity and cost while maintaining mechanical protection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly increases fiber density, reduces cable diameter, and enhances mechanical strength, temperature resistance, and moisture resistance, thereby decreasing installation costs and improving the cable's ability to navigate through ducts and micro-ducts while maintaining high capacity.
Implementation Method 1
Each optical fiber is covered with a coating of colored UV-curable (silicone-acrylate) resin, so that the outer diameter of each optical fiber reaches 180 to 250 microns
Implementation Method 2
The use of fiber-reinforced polymer (FRP) in the optical fiber unit, where optical fibers are embedded within an FRP cross-section during the Pultrusion process, providing enhanced mechanical protection
Implementation Method 3
optical fibers are embedded within an FRP cross-section during the Pultrusion process
Data Source
AI summary
The present invention is an optical fiber unit (cable) made from a coated optical fiber with UV-curable resin that is integrated into a cross-section of Fiber-reinforced polymer (FRP) composite to provide more mechanical protection for the optical fiber. In the first stage, the optical fiber is covered with a coating of acrylic or silicon UV-curable resin, and then all or a part of the cross-section of the optical fiber is placed in a fiber-reinforced polymer (FRP) that is cured by UV in Pultrusion process. Then, the composition is covered by thermoplastic polymers. At least one optical fiber is regularly located on the cross-section or outer surface of an FRP in such a way that all or part of the cross-section of the optical fiber is placed in the cross-section of FRP cross-section.